Hydrothermally synthesized porous kaolinite as a carrier for a biocatalyst

Abstract: Hydrothermally synthesized porous kaolinite is used as a carrier in a bioreactor. The carrier-biocatalyst composite includes the synthesized kaolinite as carrier and a biocatalyst, such as an enzyme, fixed onto the synthesized kaolinite. Improved fixing of the enzyme can be achieved.

Description: The present invention is directed to use of porous synthesized kaolinite as an inorganic carrier for a biocatalyst, such as an enzyme, to be charged into a bioreactor. The invention also relates to a biocatalyst carrier-biocatalyst composite and a bioreactor system using such a composite, as well as to a method of making the composite. It has been known for a long time that enzymes are adsorbed on synthesized macromolecular materials or enzymes are enclosed and fixed by gels in order to industrially effect bioreaction by using the enzymes. Since these carriers are inorganic materials, they unfavourably have low strength, and are unsuitable in increasing the size of the carrier. For this reason, it has been recently common to use purified inorganic minerals, such as silica and alumina, as carriers. However, for example, when silica is used as a carrier, there is a problem that since silica is likely to be damaged with alkali, it cannot be used over a entire pH range. When alumina is used as a carrier, there is a problem that an amount of an enzyme fixed on the carrier cannot be increased. Further, when a natural inorganic mineral is used as a carrier, such a mineral inevitably contains impurities. Consequently, it is feared that ions such as Ca ++ and K + , which the enzyme dislikes, dissolves out, and thus the activity of the fixed enzyme is deteriorated. J.M. Adam et al. International Biotechnology Laboratory 6(3): 22-27 (1988) describes ceramic biosupports derived from the clay mineral kaolinite. It is an object of the present invention to solve or reduce the above-mentioned problems, and the invention can provide carriers for a biocatalyst which can be stably used over the entire pH range, or have a large capacity of fixing an enzyme thereon, or do not contain impurities which dissolve out to deteriorate the activity of the enzyme. The invention in one aspect consists in use of porous synthesized kaolinite as a biocatalyst carrier, the synthesized kaolinite being synthesized by hydrothermal crystallization. The invention further consists in a carrier-biocatalyst composite comprising porus synthesized kaolinite as a carrier and a biocatalyst such as an enzyme supported on the carrier, the synthesized kaolinite being synthesized by hydrothermal crystallization. The invention also provides a bioreactor system comprising a bioreactor vessel, and a carrier-biocatalyst composite as defined above in the bioreactor vessel. The invention also consists in a method of making a carrier-biocatalyst composite as defined above, comprising the steps of forming a synthesized kaolinite by hydrothermal crystallisation and contacting the biocatalyst with the synthesized kaolinite to establish support of the biocatalyst thereon. The hydrothermally synthesized porous kaolinite may be in the form of a honeycomb structural body, a cylindrical body, a rod shape, a planar shape, a block shape, pellets, or granules, and the synthesized kaolinite may be produced in any appropriate form by using a conventional process such as molding, casting, extruding, pressing granulating. Further, the invention relates to a bioreactor system including a bioreactor vessel and such a carrier-biocatalyst composite body placed in the bioreactor vessel. For example, the carrier-biocatalyst composite body may be formed by placing the carrier inside the bioreactor vessel and passing a liquid, such as glucoside, containing the biocatalyst through the carrier. According to the present invention, the following are considered preferable, but not essential. (1) The hydrothermally synthesized kaolinite has a pore diameter distribution with at least a peak of fine pores in a range of 40 nm to 60 nm. (2) The average particle size of the crystals of the hydrothermally synthesized kaolinite is 0.1 µm to 0.5 µm. (3) The volume percentage of pores having diameters falling in the range of 40 nm to 60 nm per the total volume of pores of the hydrothermally synthesized kaolinite is not less than 40%, more preferably 40%∼70%. The total volume (cm 3 /g) of the pores falling in the pore sizes of 40 nm to 60 nm is 0.45 cm 3 /g, more preferably 0.45 cm 3 /g to 0.55 cm 3 /g. These and other optional features and advantages of the invention will be appreciated upon reading of the following description of the invention when taken in conjunction with the attached drawings with the understanding that modifications, variations and changes of the same could be easily made by the skilled person in the art to which the invention pertains. For a better understanding of the invention, reference is made to the attached drawing, wherein: Fig. 1 is a graph showing a fine pore diameter distribution of a synthesized kaolinite used as a biocatalyst carrier in the Example together with those of Gairome clay and Georgia kaoline. As the synthesized kaolinite used in the present invention, there may be used a kaolinite synthesized through hydrothermal crystallization by heating a mixed fine powder of SiO 2 and Al 2 O 3 in an acidic solution. For example, see Gastuche, M.C., and La Iglesia. A "Clays and Clay Materials", 26,409 (1978), and S. Tomura, Y. Shibasaki and H. Mizuta "Clays and Clay Materials", Vol. 33, pp200∼206 (1985). For example, when the synthesized kaolinite is used in the granular form, the synthesized kaolinite is granulated by preparing a slurry of a hydrothermally synthesized kaolinite and then spraying the slurry with a spray dryer. The particle diameters of the granules are not limited to any range, but the average particle diameter of the granules is preferably in a range of 10-1000 µm from the standpoint of handling. In order to remove an organic binder added to the slurry in the granulation with the spray dryer, it is preferable to calcine the granules at 650°C-850°C for more than 1 hour in an electric furnace. If the calcining temperature is less than 650°C, the strength of the carrier may become lower, whereas if the calcining temperature is more than 850°C, fine pores may not be obtained as desired. If the calcining time is less than 1 hour, strength becomes lower. The granules of the resulting synthesized kaolinite are charged in a cylinder, which is set inside a reactor vessel of a bioreactor. It is preferable that a peak exists in a range of 40 nm to 60 nm in the pore diameter distribution of the calcined granules. If the diameter of the pore is less than 40 nm, the enzyme may not easily enter the pore, whereas if it is more than 60 nm, the specific surface area decreases. In either case, the fixed amount of the enzyme decreases. The volume of pores having diameters falling in the range of 40 nm to 60 nm per the total volume of the pores of the thus obtained porous kaolinite is preferably not less than 40%. When the synthesized kaolinite is used in the form of a honeycomb structure, a cylindrical shape, a rod-like shape, a planer shape, or a block-like shape, the kaolinite is shaped by a conventional process such as molding, pressing, extruding, casting or the like. In this case, the above heat treatment may be effected. The synthesized kaolinite thus prepared is compared with natural kaolinite as follows: Natural kaolinite Synthesized kaolinite Average face (AB) size 10 ∼ 0.5 µm not more than 0.3 µm Chemical analysis (Impurity) Fe 2 O 3 0.5 ∼ 2.0 not more than 0.2% TiO 2 0.8 ∼ 1.0 not more than 0.2% CaO 0.18 ∼ 0.24 not more than 0.2% MgO 0.35 ∼ 0.50 not more than 0.2% K 2 O 0.50 ∼ 0.70 not more than 0.1% Na 2 O 0.09 ∼ 1.00 not more than 0.1% C-face edge thickness (nm) 15 ∼ 40 15 As shown by data in examples mentioned later, the thus constituted biocatalyst carrier according to the present invention has a number of fine pores having such sizes as suitable for carrying the enzyme, and the amount of the enzyme fixed can be increased up to about two times as much as the conventionally fixed amount. Further, kaolinite has a chemical structure of Si 2 Al 2 O 5 (OH) 4 , and possesses four OH-groups per one molecule to promote the fixture of the enzyme onto the carrier. Accordingly, the amount of the fixed enzyme can not only be increased, but also the rate of the fixed but peeled enzyme during use can be suppressed to a low level. Furthermore, since the carrier used in the present invention is constituted by the hydrothermally synthesized kaolinite, the carrier has a merit that it does not dissolve out ions such as Ca ++ and K + which the enzyme dislikes unlike the conventional carriers. In addition, since the carrier used in to the present invention is constituted by the hydrothermally synthesized kaolinite, the carrier is difficult to damage with acid and alkali, and the carrier can be stably used in the entire pH range. Moreover, the synthesized kaolinite is finer and more uniform than natural kaolinite in that the individual particle size of the crystals of the hydrothermally synthesized kaolinite is ordinarily 0.1-0.5 µm, whereas the minimum particle size of those of natural kaolinite is not less than 0.5 µm. Therefore, the synthesized kaolinite according to the present invention is suitable for fixing the enzyme thereon. The enzymes which may be carried and fixed onto the bioreactor carrier according to the present invention are not limited to any specific ones, so long as the objects of the present invention can be realized. As examples, α-glucosidase, saccharase, phosphatase catalase, lipase, and protease may be recited. As the bioreactor system, ordinary bioreactor equipments may be used. In this bioreactor system, the carrier-biocatalyst composite body is placed in a reactor vessel. In the following, examples of the present invention will be explained together with comparative examples. A slurry having a content of water being about 30% was prepared by kneading a hydrothermally synthesized kaolinite commercially available under a tradename of TD-series from TOYO DENKA Co., Ltd. together with an organic binder and water, and the slurry was subjected to granulation with a spray dryer. The granular material was calcined at 750°C for 4 hours to remove the organic binder, thereby obtaining a granular product having the average particle diameter of 70 µm. The specific surface area of the granulate was measured to be 47 m 2 /g by the BET method. The pore diameter distribution was determined by the measurement according to the mercury press-in method. As shown in the graph of Fig. 1, a peak is observed in a range of 40 nm to 60 nm in the pore diameter distribution. The granulate obtained above (Example) was charged into a cylinder, and an enzyme (α-glucosidase) was fixed onto the granulate as a carrier. Then, an amount of the enzyme per one gram of the carrier, a rate of the enzyme removed from the carrier after a lapse of time of 10-90 minutes since the start of the measurement, an amount of the retained enzyme after the lapse of time of 90 minutes and the activity (U) of glucosidase per one gram of the fixed enzyme were measured. For the comparison purpose, needle-shaped silica, commercially available silica, and sepiolite were subjected to the same measurements as given above. The pore diameter distributions of the needle-shaped silica, commercially available silica, and sepiolite are also shown in Fig. 1. Results are shown in Table 2. The chemical analysis values of the hydrothermally synthesized kaolinite commercially available under a trade name TD from TOYO DENKA Co., Ltd. are as follows: SiO 2 46-48 wt% Aℓ 2 O 3 36-38 wt% Fe 2 O 3 ≦0.25 wt% TiO 2 ≦0.15 wt% (Average particle size ≦1 µm) For Example, Si 47.42 wt%, CaO 0.19 wt% Aℓ 2 O 3 37.34 wt%, Na 2 O 0.10 wt% Fe2O 3 0.19 wt%, K 2 O 0.03 wt% TiO 2 0.12 wt%, MgO 0.14 wt%, Ig. loss 13.48 wt% In the above, the activity of glucosidase was measured as follows: Ten mM of a buffer solution of acetic acid containing 1 wt% of α-methyl-D-glucoside (adjusted to pH 5) was poured in a total amount of 20 cm 3 into a vessel, and a granular carrier was charged thereinto. Then, 200 mg of the carrier on which was carried the immobilized α-glucosidase was added to the buffer solution. After the reaction for 1 hour, an amount of released glucose in 100 µℓ of the reaction mixture sampled with 100 µℓ Na 2 Co 3 was measured by the glucose-oxidase method (For example, see Miwa, I., Okuda, J., Maeda, K. and Okuda, G., "Clin. Chim. Acta." vol. 37, pp 538-540 (1972)). In this experiment, the total volume (cm 3 /g) of the pores falling in the pore size range of 40 nm - 60 nm was shown together with the percentage of the volume (cm 3 /g) of pores falling in the range 40 nm - 60 nm per the total pore volume (cm 3 /g). synthesized kaolinite sepiolite Gairome clay Total volume (cm 3 /g) of the pores falling in the pore size of 40 nm - 60 nm 0.5 0.42 0.20 Volume of pores falling in 40 nm - 60 nm Total pore volume 63% 36% 27% As shown in Table 2, the bioreactor carrier in the above Example had a larger amount of the enzyme fixed thereon, a lower peeled-off rate of the enzyme and a larger activity of glucosidase per one gram of the fixed enzyme as compared with Comparative Examples. As explained above, the bioreactor carrier according to the present invention is composed of the hydrothermally synthesized porous kaolinite, and the particle size of the kaolinite is very small. Further, the carrier preferably has a large number of such pores having in the distribution with the peak in a range of 40 nm - 60 nm as suitable for fixing the enzyme, so that the amount of the enzyme fixed on the carrier is large. In addition, since the bioreactor carrier according to the present invention contains substantially no impurities unlike natural kaoline, and does not dissolve out impurities which may damage the activity of the enzyme. Further, the bioreactor carrier can be stably used over the entire pH range, since the carrier is strong against acid and alkaline.

Claims: Use of porous synthesized kaolinite as a biocatalyst carrier, said synthesized kaolinite being synthesized by hydrothermal crystallization. Use as set forth in claim 1, wherein said synthesized kaolinite is used in a shape selected from a honeycomb structure, a cylindrical shape, a rod shape, a planar shape, a block shape, a pellet shape and a granular shape. Use as set forth in claim 1 or 2, wherein said synthesized kaolinite has a pore diameter distribution having a peak in the range of 40 nm to 60 nm. Use as set forth in claim 3, wherein the volume percentage of pores having diameters falling in the range of 40 nm to 60 nm per total pore volume of the hydrothermally synthesized kaolinite is not less than 40%. Use as set forth in any one of claims 1 to 4 wherein the particle sizes of crystals of the hydrothermally synthesized kaolinite are in the range 0.1 - 0.5 µm. Use as set forth in any one of claims 1 to 5 wherein the hydrothermally synthesized kaolinite has been calcined at 650°C to 850°C. A carrier-biocatalyst composite comprising porous synthesized kaolinite as a carrier and a biocatalyst supported on said carrier, said synthesized kaolinite being synthesized by hydrothermal crystallization. A carrier-biocatalyst composite as set forth in claim 7, wherein said synthesized kaolinite is in the shape selected from a honeycomb structure, a cylindrical shape, a rod shape, a planar shape, a block shape, a pellet shape and a granular shape. A carrier-biocatalyst composite as set forth in claim 7 or 8, wherein said synthesized kaolinite is as defined in any one of claims 3 to 6. A carrier-biocatalyst composite as set forth in any one of claims 7 to 9 wherein said biocatalyst is selected from α-glucosidase, saccharase, phosphatase and catalase. A bioreactor system comprising a bioreactor vessel, and a carrier-biocatalyst composite according to any one of claims 7 to 10 in said bioreactor vessel. A method of making a carrier-biocatalyst composite according to any one of claims 7 to 10, comprising the steps of forming a synthesized kaolinite by hydrothermal crystallization and contacting said biocatalyst with the synthesized kaolinite to establish support of the biocatalyst thereon.

Inventors: TONE KISATO, TONE, KISATO, TONE, KISATO, 70-2 AZA-NAKAHATA
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1994
Main classification: C12N11
IPC codes: C12N11